Professional Documents
Culture Documents
Foundry or casting is the process of producing metal/alloy component parts of desired shapes by pouring the molten metal/alloy into a prepared mould (of that shape) and then allowing the metal/alloy to cool and solidify. The solidified piece of metal/alloy is known as a CASTING.
Casting Terms:
Flask: A metal or wood frame, without fixed top or bottom, in which the mold is formed. drag - lower molding flask, cope - upper molding flask, cheek - intermediate molding flask used in three piece molding. 2. Pattern: It is the replica of the final object to be made. The mold cavity is made with the help of pattern. 3. Parting line: This is the dividing line between the two molding flasks that makes up the mold.
1.
4. Core: A separate part of the mold, made of sand and generally baked, which is used to create openings and various shaped cavities in the castings. 5. Pouring basin: A small funnel shaped cavity at the top of the mold into which the molten metal is poured. 6. Sprue: The passage through which the molten metal, from the pouring basin, reaches the mold cavity. In many cases it controls the flow of metal into the mold. 7. Runner: The channel through which the molten metal is carried from the sprue to the gate.
8. Gate: A channel through which the molten metal enters the mold cavity. 9. Chaplets: Chaplets are used to support the cores inside the mold cavity to take care of its own weight and overcome the metallostatic force. 10. Riser: A column of molten metal placed in the mold to feed the castings as it shrinks and solidifies. Also known as feed head. 11. Vent: Small opening in the mold to facilitate escape of air and gases.
Basic Features:
Pattern and Mould
A pattern is made of wood or metal, is a replica of the final product and is used for preparing mould cavity. Mould material should posses refractory characteristics and with stand the pouring temperature.
Ken Youssefi
10
Applications of Casting:
Transportation
vehicles
Turbine
vanes Power generators Railway crossings Agricultural parts Aircraft jet engine parts Sanitary fittings Communication, Construction and Atomic Energy applications, etc..
NON-FERROUS:
a. b. c. d. e. Copper alloys Aluminium alloys Magnesium alloys Zinc alloys Nickel alloys
Pattern Making:
A Pattern
is a model or the replica of the object to be cast. Except for the various allowances a pattern exactly resembles the casting to be made. A pattern is required even if one object has to be cast.
Functions of Patterns:
A Pattern prepares a mould cavity for the purpose of making a casting. A Pattern may contain projections known as core prints if the casting requires a core and need to be made hollow. Patterns properly made and having finished and smooth surfaces reduce casting defects. Properly constructed patterns minimize overall cost of the casting.
Easily worked, shaped and joined. Light in weight. Strong, hard and durable. Resistant to wear and abrasion . Resistant to corrosion, and to chemical reactions. Dimensionally stable and unaffected by variations in temperature and humidity. Available at low cost.
d.
e.
Types of Patterns:
1. 2. 3. 4. 5. 6. 7. 8. 9. Single piece pattern. Split piece pattern. Loose piece pattern. Match plate pattern. Sweep pattern. Gated pattern. Skeleton pattern Follow board pattern. Cope and Drag pattern.
(a)Split pattern (b) Follow-board (c) Match Plate (d) Loose-piece (e) Sweep (f) Skeleton pattern
Sweep pattern:
castings
Gating system
GATED PATTRN
GATED PATTRN
1.Shrinkage Allowance:
All most all cast metals shrink or contract volumetrically on cooling.
2. Machining Allowance:
A Casting is given an allowance for machining, because:
Castings get oxidized in the mold and during heat treatment; scales etc., thus formed need to be removed. ii. It is the intended to remove surface roughness and other imperfections from the castings. iii. It is required to achieve exact casting dimensions. iv. Surface finish is required on the casting.
i.
It is given to all surfaces perpendicular to parting line. Draft allowance is given so that the pattern can be easily removed from the molding material tightly packed around it with out damaging the mould cavity.
5. Shake allowance:
A
patter is shaken or rapped by striking the same with a wooden piece from side to side. This is done so that the pattern a little is loosened in the mold cavity and can be easily removed.
In
turn, therefore, rapping enlarges the mould cavity which results in a bigger sized casting.
a ve allowance is provided on the pattern i.e., the pattern dimensions are kept smaller in order to compensate the enlargement of mould cavity due to rapping.
Hence,
Pattern Layout:
Steps involved:
Get the working drawing of the part for which the pattern is to be made.
Make two views of the part drawing on a sheet, using a shrink rule. A shrink rule is modified form of an ordinary scale which has already taken care of shrinkage allowance for a particular metal to be cast. Add machining requirements. allowances as per the
Pattern Construction:
Study
the pattern layout carefully and establish, a. Location of parting surface. b. No. of parts in which the pattern will be made. Using the various hand tools and pattern making machines fabricate the different parts of the pattern. Inspect the pattern as regards the alignment of different portions of the pattern and its dimensional accuracy. Fill wax in all the fillets in order to remove sharp corners. Give a shellac coatings(3 coats) to pattern. impart suitable colors to the pattern for identification purposes and for other informations.
Moulding Materials
Major part of Moulding material in sand casting are 1. 70-85% silica sand (SiO2) 2. 10-12% bonding material e.g., clay cereal etc. 3. 3-6% water Properties of molding sand are: (a) Refractoriness (b) Cohesiveness (c) Strength/Adhesiveness (d) Permeability (e) Collapsibility (f) Flowability (g) Chemical Inactiveness
2.
3. 4. 5. 6.
7.
Green Sand Dry Sand Facing Sand Loam Sand Backing Sand Parting Sand Core Sand
Melting furnace
Knock out
Heat treatment
Machining
Casting Methods
Sand Casting
High Temperature Alloy, Complex Geometry, Rough Surface Finish
Investment Casting
High Temperature Alloy, Complex Geometry, Moderately Smooth Surface Finish
Die Casting
High Temperature Alloy, Moderate Geometry, Smooth Surface
65